Outdoor furniture with protective layers

ABSTRACT

An article of furniture comprising, in combination: a core body consisting of first plastic foam material, a first layer extending at one or more of the top and sides of the core, and attached to the core, consisting of plastic soft material, a second layer covering the first layer and covering the top and sides of the body, and which is a waterproof plastic film material, and an outer exposed sheet removably covering said second layer, and consisting of an upholstery material or the like.

BACKGROUND OF THE INVENTION

This application claims priority from provisional application Ser. No. 60/802,692 filed May 24, 2006.

This invention relates generally to durable, outdoor furniture, and more particularly to lounge type furniture having very durable weatherproof construction and methods of making same.

There is continual need for inexpensive, attractive, and durable, block type outdoor furniture, of single, easy to manufacture construction. There is also need for block type furniture items of unusually advantageous layered construction, modes of operation or use, and having associated useful results.

SUMMARY OF THE INVENTION

It is a major object of the invention to provide furniture pieces satisfying the above expressed needs. Basically, the new and useful article of furniture comprises, in combination

a) a core body consisting of first plastic foam material,

-   -   b) a first layer extending at one or more of the top and sides         of the core body, and attached to the core body, and consisting         of plastic soft material,     -   c) a second layer covering the first layer and covering the top         and sides of the body, and which is a waterproof plastic film         material,     -   d) and an outer exposed sheet removably covering said second         layer, and consisting of a wear resistant fabric material.

As will be seen, a plastic foam bottom layer may be bonded to the second layer.

Another object is to provide a method of integrating the body, layers and outer covering, as referred to.

A further object is to optimize the construction and use of such block type furniture by providing the core body to consist of expanded polystyrene or other fairly rigid polymer foam for load bearing seat requirements; providing the first layer cushioning material to consist of soft polyethylene foam which may be located at the body sides, and polyurethane foam at the body top; providing the second waterproofing layer to consist of polyolefin plastic sheet material; and providing the outer sheet removable cover to consist of vinyl upholstery grade material such as woven acrylic thread and at the bottom of cross-linked polyethylene (YLPE) foam. In this way, the in situ cover can be exposed to rain or other water sources, and will dry in sunlight, and the second waterproof layer will protect the first layer and core from contact with water to retain maximum cushioning function irregardless of the wetted condition of the cover and irregardless of whether the cover is on or off the block.

Additional objects include provision of articles of furniture having the above construction and also having configuration of a disc of diameter D₁ and height H₁ overlying and merging with a cylinder of diameter D₂ and height H₂ where D₁>D₂ H₁<H₂; and further with the disc overhanging the cylinder by a radial amount R where R<D₁; and further with an optimized canopy overlying and spaced above part of the disc, and an upright strut connecting the canopy to the disc.

Other furniture configurations include a base beneath an upright cylinder and offset radially inwardly relative to the cylinder periphery; a tray supported at an upper surface of the block which may have various shapes as will be seen; and a lounge configuration with upper surface sections sloping at several varying angularities, as will be seen.

These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:

DRAWING DESCRIPTION

FIG. 1 is a perspective view of an article of furniture in play-pad configuration;

Fig. 1 a shows a modification to FIG. 1;

FIG. 2 is a perspective view of a cylindrically shaped article of furniture;

FIG. 3 is a view of a top tray applicable to the top of FIG. 2 cylinder;

FIG. 4 is a perspective view of a cube shaped article of furniture;

FIG. 5 is a view of a tray applicable to the top of the FIG. 4 article;

FIG. 6 is a perspective view of an elongated article of box-like configuration;

FIG. 6 a is a view of a tray applicable to the top of the FIG. 6 article;

FIGS. 7-11 are views of cube-like articles construction;

FIG. 12 is a perspective view of an article of furniture in the form of a block-like lounge, with top surface angularities;

FIG. 13 is an enlarged fragmentary section taken through an article of furniture showing its layered construction, with corner supports.

DETAILED DESCRIPTION

Referring first to FIG. 13, the elements of the preferred block like article 10 of furniture include:

-   -   a) a core body 11 consisting of a first plastic foam material,     -   b) a first layer 13 extending at one or more of the top and         sides of the core body, as at 13 a, 13 b and 13 c, attached to         the core body, and consisting of a soft plastic material, for         cushioning, with a bottom layer 22 of additional cushioning         material, below corner supports 21,     -   c) a second layer 14 covering layers 122 and 13 a, and covering         the top, sides and part of the bottom of the body, as at 14 a-14         d, and which is a waterproof plastic film material,     -   d) and an outer exposed sheet 15 removably covering the second         layer, as at 15 a-15 d, and typically consisting of a wearable         material, such as marine grade vinyl or upholstery fabric or         terry cloth.

Another layer 122 may be used and consist of polyurethane foam provided to add cushioning on top of 13 a; rigid or semi-rigid lower corner supports 121 may also be employed, as shown and as referred to.

The core body 11 typically consists of EPS, i.e. expanded polystyrene foam; the first layer 13 typically consists of polyethylene foam, with adhesive connecting it to 11; the layer 122 typically consists of polyurethane foam, and corner supports 121 may consist of molded plastic material at four locations about the core; the second layer 14 typically consists of polypropylene film, heat shrunk into a over layer 13 about the entireties of 11 and 13 and 122; and the outer sheet 15 is fitted over sheet 14 and releasably connected in position, as for example by a draw string or strip 17 passed through loops 16 at the lower edge of 15, beneath the edge portions of the body such as below 14 d. String or strings 17 pull the loops 16 toward a zone beneath the lower medial portion of the body 11, for tightening outer layer 15 in position maintaining substantially sharp or crisp upper edges 13 f, 14 f, and 15 f of 13, 14 and 15, respectively. Velcro fastening is an alternative. Layer 15 is easily removable, as for cleaning.

A base 19 is shown adhered (as by adhesive) at 20 to the lowermost extent 14 d of the film 14 under the body 11, to extend inwardly of and below the levels of loops 16, for their protection. Base 19 typically consists of cross-linked polyethylene foam which provides high strength.

The thickness t₁ of the various elements are as follows: 122 t₁ - 1.5 inches on top. 13 t₁ .25 inch on sides and on top 14 t₁ - .003 to .004 inch 15 t₁ - .10 inch 19 t₁ - .75 inch

Accordingly, the furniture provides cushioning; waterproofing; and wearability of an outer layer 15, removable for cleaning or replacement; and sturdy support on a base 19 of width which is over 60% of body width, to prevent overturning when the article of furniture is sat upon, as near its top edge. The illustrated article is a cube of approximately 18 inch edge dimensions.

Referring now to FIGS. 1 and 1 a, the article of furniture 26 embodying FIG. 13 construction, has the configuration of a disc 21 of diameter D₁, and height H₁, overlying and merging with a short upright cylinder 22 of diameter D₂ and height H₂, where D₁>D₂ H₁<H₂.

As shown, the disc and cylinder are coaxial and the disc peripheral zone 21 a annularly overhangs the cylinder by a radial amount R where R<<D₁.

Each of 21 and 22 embody FIG. 13 construction. Top and side wall zones, as well as the underside of disc 21 overhang the side of the cylinder 22. Disc 21 and cylinder 22 may each be formed as two semicircular halves, with edge to edge engagement.

In FIG. 1 base 24 underlies the bottom of the cylinder, also indicated at 19 in FIG. 13, and may be suitably attached to that bottom, as by adhesive 20. The disc and cylinder surfaces are completely enclosed as by film layer or layers 14. A cover sheet for disc 21 may terminate downwardly and inwardly, adjacent the side of 22, above the base 24, to be easily removable. Core 11 remains waterproof protected, for cushioning whether or not the furniture is contacted by water. Fig. 1 a is like FIG. 1, but shows a canopy 27 extended over part of the disc and supported by upright strut 28, the lower part of which is received in an opening 29 in the disc, for support.

FIG. 2 shows an article of furniture in upright cylinder form 31 and having construction as in FIG. 13. Broken lines 32 and 33 indicate edge seams (as by stitching) in the outer cover material 15, which is removable, as referred to. A base or base elements 34 corresponding to 24 in FIG. 1, adhere to the bottom of the article, in the manner as disclosed in FIG. 13. FIG. 3 shows a cover or lid 35 that fits on the top of the cylinder 31, and includes cushioning plastic material in its construction.

FIG. 4 shows cube form 40 of the article of furniture, and has a top 41 and four side walls 42. It also has the construction as disclosed in FIG. 13. A base or base elements 43 adhere to the bottom of the cube. FIG. 5 shows a tray 44 that is channel shaped to fit onto the top of the cube. The tray area may be less than top wall 41 area.

The furniture 50 of FIG. 6 is like FIG. 4, but is elongated, and also has the construction of FIG. 13. Side and end walls appear at 51 and 52. A horizontal top wall is designated at 53, and sealed seams in the cover appear at 54 and 55 adjacent sharp edges 56 and 57. A cushioning cover or lid for 50 is shown at 58 in FIG. 6 a, and has channel shape. It may also define a tray.

FIGS. 7-11 show the construction of a modified cube form article 40 a. The layers 14 and 15 are here defined by separate layers at each of the top and side walls. See for example separated top layers 13 a′, 14 a′ and 15 a′; and separated side layers 13 b′ and 14 b′ , at each side.

FIG. 12 shows an elongated lounge body 80 having FIG. 13 construction. The top surfaces 81-84 are relatively angled, as in S or wave shape, as shown. See also bottom support layer 19′. A first top surface has angularity α, relative to horizontal, a second and next in sequence top surface has angularity −α₂, and the next in sequence top surface has angularity α₃ relative to horizontal, where α₃>α₁ −|α₂|<α₁ −|α₂|<α₃

Kindly amend the paragraph beginning at page 6, line 19, as follows:

-   -   b) a first layer 13 extending at one or more of the top and         sides of the core body, as at 13 a, 13 b and 13 c, attached to         the core body, and consisting of a soft plastic material, for         cushioning, with a bottom layer 22 of additional cushioning         material, below corner supports 121, 

1. An article of furniture comprising, in combination: a) a core body consisting of first plastic foam material, b) a first layer extending at one or more of the top and sides of the core, and attached to the core, consisting of plastic soft material, c) a second layer covering the first layer and covering the top, and sides and bottom of the body, and which is a waterproof plastic film material, d) and an outer exposed sheet removably covering said second layer, and consisting of an upholstery material or the like.
 2. The combination of claim 1 wherein said plastic foam material of said body consists of expanded polystyrene, and has block shape.
 3. The combination of claim 1 wherein said first layer consists of soft polyethylene foam.
 4. The combination of claim 1 wherein said layer consists of polyolefin plastic sheet material.
 5. The combination of claim 1 wherein said sheet consists of upholstery grade vinyl and is removable open covering relation to said second layer.
 6. The article of claim 1 which has a configuration of a disc of diameter D₁ and height H₁ overlying and merging with a cylinder of diameter D₂ and height H₂ where D₁>D₂ H₁<H₂
 7. The article of claim 6 wherein the disc overhangs the cylinder by a radial amount R where R<D₁
 8. The article of claim 6 including a canopy overlying and spaced above part of the disc, and an upright strut connecting the canopy to the disc.
 9. The article of claim 6 including a base beneath the cylinder and offset radially inwardly relative to the cylinder periphery.
 10. The article of claim 1 having the configuration of an upright cylinder, and a base beneath the cylinder.
 11. The article of claim 10 including a tray supported on the uppermost surfaces of the cylinder.
 12. The article of claim 1 having the configuration of an elongated box with opposite parallel sides, and horizontal length substantially exceeding box height.
 13. The article of claim 12 including a tray supported on an upper surface o the box, the tray having length substantially less than box length.
 14. The article of claim 1 having substantially the configuration of a cube.
 15. The article of claim 1 comprising a lounge with multiple flat top surfaces.
 16. The article of claim 15 wherein a first top surface has angularity α, relative to horizontal, a second and next in sequence top surface has angularity—α₂, and the next in sequence top surface has angularity α₃ relative to horizontal, where α₃>α₁ −|α₂|<α₁ −|α₂|<α₃
 17. The article of claim 1 including a tray applicable to the top of said article, there being flange means on the tray to embrace said article.
 18. The article of claim 1 including a base adhered to said film.
 19. The article of claim 18 wherein the base consists of cross linked polyethylene foam.
 20. The combination of claim 1 wherein said first layer has thickness t₁, said second layer has thickness t₂, and said outer sheet has thickness t₃ where t₁>t₂ t₃>t₁
 21. The combination of claim 20 wherein t₁— 1/4inch t₂—0.003 to 0.004 inch t₃— 3/4inch
 22. The combination of claim 1 wherein i) said first layer consists essentially of polyurethane foam on top and polyethylene foam on the sides; ii) said second layer consists essentially of polypropylene heat shrinkable film; iii) said outer sheet consists of upholstery grade vinyl.
 23. The combination of claim 22 including means removably connecting the outer sheet in position.
 24. The combination of claim 13 wherein said means is a drawstring or stretchable cord tied proximate the bottom of said article.
 25. The combination of claim 1 including a cushioning pad contained under said second layer and said covering sheet.
 26. The combination of claim 25 wherein said pad is recessed downwardly in a cavity frame by said first and second layers.
 27. The combination of claim 24 wherein said body is elongated and said drawstring extends beneath said body.
 28. The combination of claim 1 wherein said body has sharp corners, and said layers and sheet conform to said corners, and there being corner supports acting to support a layer or layers at the side of the body.
 29. The combination of claim 28 wherein said body has internal reinforcement at lower corners, under said second layer, providing structural support to maintain the corners substantially sharp, externally, under the tensioned covering sheet. 